Lab session: 07

Experiment Title:

6) To measure surface roughness of Al plate by using tools, Brass ,Cu and Al

by using EDM die Sinker.

Electrical discharge machining

6.1) Introduction:

Electrical discharge machining (EDM), also known as spark machining, spark eroding, burning, die
sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained by
using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly
recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an
electric voltage. One of the electrodes is called the tool-electrode, or simply the "tool" or "electrode,"
while the other is called the workpiece-electrode, or "work piece." The process depends upon the tool and
work piece not making actual contact.

6.2) Sinker EDM:

The Sinker EDM is also called a volume EDM or cavity EDM. This has got a work piece and an
electrode present in an insulating fluid. The work piece and the electrode are connected with specific
supply of power. Due to the power electrical potential is created between the two components. When
the electrode reaches the work piece then the dielectric discharged is released and forms a plasma
channel with slight sparks.

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6.3) Surface roughness:

Whatever may be the manufacturing process used, it is not possible to produce perfectly smooth surface.
The imperfections and irregularities are bound to occur. The manufactured surface always departs from
the absolute perfection to some extent. The irregularities on the surface are in the form of succession of
hills and valleys varying in height and spacing. These irregularities are usually termed as surface
roughness, surface finish, surface texture or surface quality. These irregularities are responsible to a great
extent for the appearance of a surface of a component and its suitability for an intended applications.

6.4) Factors Affecting Surface Roughness:

The following factors affect the surface roughness:

1) Vibrations

2) Material of the workpiece

3) Type of machining.

4) Rigidity of the system consisting of machine tool, fixture cutting tool and work

5) Type, form, material and sharpness of cutting tool

6) Cutting conditions i.e., feed, speed and depth of cut

7) Type of coolant used

6.4) Reasons for Controlling Surface Texture:

1) To improve the service life of the components

2) To improve the fatigue resistance

3) To reduce initial wear of parts

4) To have a close dimensional tolerance on the parts

5) To reduce frictional wear

6) To reduce corrosion by minimizing depth of irregularities

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 7) For good appearance

6.5) Surface roughness meter:

It shows the measured roughness depth (Rz) as well as the average roughness value (Ra) in µm.
Roughness testers allow a user to determine the material surface roughness quickly. The measurement
of surface roughness is very easy. Roughness testers get in contact with surfaces within a few seconds
and show the roughness value in Ra or in Rz. Our Roughness testers will be delivered with control cards,
probe protection, accumulators and chargers inside a carrying case.

6.6) Observations & calculations:

6.6.1) Work piece Al & Tool Cu

Depth of cut = 10mm

Current = 21A

Time to produce surface roughness = 3 mint + 7 sec

Readings from surface roughness meter

Ra =4.70

Rt =46.00

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Rz =27.00

6.6.2) Work piece Al & tool brass

Depth of cut = 10mm

Current = 21A

Time = 4mints

Readings from surface roughness meter

Ra =2.70

Rt =24.50

Rz =16.00

6.6.3) Work piece Al & tool Al

Depth of cut = 10mm

Current = 21A

Time = 3mints+ 55sec

Readings from surface roughness meter

Ra =2.60

Rt =21.00

Rz =15.00

6.7) Advantages of die sink EDM:

 Sinker EDM process can do wonders for your production industry and provides durable results
with high-quality finishes. Following are the advantages of Sinker EDM:
 Cuts exotic materials easily
 Tough materials are easy to cut
 Little or no polishing is required after the process is complete
 Cuts thin materials without by preventing any damage

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6.7.1) Disadvantages of die sink EDM:
 Excessive power consumption
 Slow material removal
 No or less conductive materials produced

6.8) Comments:
 Electrode wear
 Slow removal rates
 Thin brittle heat effected zone
 Expensive set up
 Expert machinist required
 Non conductive materials can’t be machined
 Can be used for special purposes

6.9)References:

1)Krar, Stephen F. and Gill, Arthur R. (2003) Exploring Advanced Manufacturing

Technologies, Industrial Press Inc. ISBN 0831131500. p. 6.2.1

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Lab session: 08

Experiment Title

7) To find the material removal rate of work pieces of various thickness by

using EDM Wire Cut.

7.1) Wire EDM:

In wire electrical discharge machining (WEDM), also known as wire-cut EDM and wire cutting, a thin
single-strand metal wire, usually brass, is fed through the workpiece, submerged in a tank of dielectric
fluid, typically deionized water.Wire-cut EDM is typically used to cut plates as thick as 300mm and to
make punches, tools, and dies from hard metals that are difficult to machine with other methods. The
wire, which is constantly fed from a spool, is held between upper and lower diamond guides which is
centered in a water nozzle head.

Fig ( EDM wire cut)

7.2) Characteristics of wire cut EDM machining:

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 1) Wire cut EDM machine is able to machine material, with high hardness, high strength, high
fragility and high tenacity, which is not easy to be or can’t be machined by conventional method,
even some semi-conductive materials are also can be processed by wire cut EDM machine.
2) There is very little heat impact on the surface of workpiece, suitable to process some heat
sensitive material; at the same time, as impulse energy concentrate on very small area, machining
accuracy is higher.
3) During machining, electrode wire doesn’t touch workpiece, there is no physical cutting force, it is
good to process workpiece with low rigidity.
4) Comparing to EDM spark erosion machine, electrode wire replaced formed electrode, saving a lot
of cost of designing and making electrode and prepared period is shortened obviously.
5) Using water-based working solution, clean and safe, especially environment-friendly.
6) Utilize electricity to do machining, electrical parameters are controllable, it is convenient to
realize whole process automatic.

7.2.1) Process parameters in WEDM:

The process parameters are known as factors which influence the nature of response variables. The
various factors affecting the surface roughness of components machined by wire-cut EDM have been
identified as:

1) Dielectric pressure

2) Pulse on time

3) Pulse off time

4) Wire tension

5) Wire feed rate

6) Gap voltage

7) Average gap current

7.2.2)Dielectric pressure:
Flushing is important in the process to achieve a stable machining condition. The pressure with which the
coolant strikes the inter-electrode gap is determined in two levels- high and low. The flushing pressure is
determined according to the material. For machining titanium, high flushing pressure is recommended.

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7.2.3)Pulse on time:
Pulse on time is the period for which the voltage is applied across the gap. It is denoted by TON. The
range of pulse on time is 1 to 10, in steps of 1. Higher the TON setting larger is the pulse on period. The
single pulse discharge energy increases with increasing TON period, resulting in higher cutting rate and
poor surface finish.

7.3)Pulse off time:

Pulse off time is the period for which voltage across the gap is absent. It is denoted by TOFF. The range
of pulse off time is 1 to 10, in steps of 1. Higher the TOFF setting larger is the pulse off period. This
results in better surface finish.

7.4.0)Wire tension:
Wire tension is a gram-equivalent load with which the continuously fed wire is kept under tension so that
it remains straight between the wire guides. Wire tension can be adjusted by the wheel provided on
machine column. While the wire is being fed continuously, appropriate wire tension prevents the
undesirable wire deflection from its straight path. The wire deflection is caused due to spark induced
reaction forces and water pressure. A brass wire of 0.25mm diameter can be applied with a maximum
tension of 1600gm. Optimum wire tension results in high MRR and low surface roughness.

7.4.1)Wire feed rate:

Wire feed rate is the rate at which fresh wire is fed continuously for sparking. It has a range of 1 to 10 in
steps of 1. Wire feed rate has great influence on MRR. With a wire feed rate of 8m/min, brass wire spool
of 5kg will last for about 24 hours.

7.4.2)Gap voltage:
Gap voltage is the potential difference across the workpiece and wire electrode. It is read directly on the
voltmeter. Gap voltage depends on the set values of gap potentiometer and sensitivity potentiometer.
Ranges between 40-60V results in better MRR and fine finish. High gap voltage gives poor finish.

7.4.3)Average gap current:

Gap current is the actual current consumed by the machining process. Its value is read on the ammeter
directly. Normally the wire can pass current of 8-10A in water. Since air bubbles are mixed in water only

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75% of the above value may be achievable. High gap currents results in high MRR and vice versa for
surface roughness.

7.5)Observations & Calculations

1) Al workpiece of thickness= 12mm

MRR= (5.5)2×12/645

MRR= 0.56mm^3/sec
2) Al workpiece of thickness= 3.5mm

MRR= (5.5)2×3.5/285

MRR= 0.37mm^3/sec

7.6) Advantages of EDM wire cut:

 Complex shapes that would otherwise be difficult to produce with conventional cutting tools.
 Extremely hard material to very close tolerances.
 Very small work pieces where conventional cutting tools may damage the part from excess
cutting tool pressure.
 There is no direct contact between tool and work piece. Therefore, delicate sections and weak
materials can be machined without perceivable distortion.
 A good surface finish can be obtained; a very good surface may be obtained by redundant
finishing paths.
 Very fine holes can be attained.

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 7.6.1)Disadvantages of EDM wire cut:

 Difficulty finding expert machinists.

 The slow rate of material removal.
 Reproducing sharp corners on the workpiece is difficult due to electrode wear.
 Specific power consumption is very high.

7.7) Comments:

 Excessive tool wear occurs during machining.

 Electrically non-conductive materials can be machined only with specific set-up of the process.
 Slow material removal rate
 Electrode wear
 Fine cracks may be produce by thermal stress
 Material to be machined must be electrically conductive
 Expensive set up

7.8) References:
1) Semon, G. (1975). A Practical Guide to Electro-Discharge Machining, 2nd ed. Ateliers des
Charmilles, Geneva.
2) Dulebohn, "Tracer controlled machining by electrically induced erosion", U.S. Patent 3,614,372,
filed 4 December 1969, issued 19 October 1971.

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 Lab session: 09

Experiment Title:

9.0) Machining of various materials through water jet cutting machine.

Water Jet Cutting Machine

9.1) Introduction:

New, difficult-to-machine materials and increased part complexity have resulted in the creation of new
manufacturing processes, known as non-traditional manufacturing processes. Water jet cutting (Fig. 1) is
one of the newest technique in non-traditional machining processes. The use of the abrasive water jet for
machining or finishing purposes is based on the principle of erosion of the material upon which the jet
hits. Each of two components of the jet, i.e. the water and the abrasive material has both a separate
purpose and a supportive purpose. It is the primary purpose of the abrasive material within the jet stream
to provide the erosive forces. It is the primary purpose of the jet to deliver the abrasive material to the
workpiece for the purpose of erosion.

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9.2) WATER JET CUTTING PROCESS

Water jet cutting technology is a unique process that is able to cut almost all materials cost effectively.
The basic technology is both simple and extremely complex. At its most basic, water flows from a pump,
through plumbing and out a cutting head. Essentially, there are two types of water jets:

(a) pure water jet cutting - WJC (Fig 2. a)

(b) abrasive water jet cutting AWJC (Fig 2. b)

Pure water jet cutting, uses only water, and found early applications cutting corrugated cardboard and
food items such as cakes and candy bars. Today, applications include cutting diapers, tissue paper and
automotive interior parts, plastics. The high pressure pump generates the required operating pressure (up
to 400 MPa). The cutting head is supplied with pressurized water by means of a high pressure supply line.
The pressurized water is relived by the nozzle (0.1 to 0.4 mm in diameter) when water jet forms and can
be utilized for cutting. When the water jet reaches its target, the energy, which the jet contains, as a result
of its speed, is changed back into impact pressure in order to get an effective amount of desired work
done on the surface.

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The abrasive water jet differs from the pure water jet in just a few ways. In pure water jet, the supersonic
stream erodes the material. An additional abrasive head is attached for abrasive water jet cutting. Solid
abrasive material is added to the water jet in a mixing chamber in the abrasive cutting head. The abusive
enriched water jet is subsequently focused in an abrasive nozzle (70 mm long and with an inside diameter
between 0.8 and 1.2 mm). The abrasive water jet is hundreds, if not thousands of times more powerful
than a pure water jet.

9.3) Influencing parameters of water jet cutting

Principal components of machine for abrasive water jet cutting (schematic shown on Fig. 3) are:

 water preparation system

 high pressure pump
 high pressure supply line
 cutting head and
 table and motion system

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Poor water quality causes mineral deposits and other problems with water nozzle and other high pressure
components and therefore one of important component of water jet cutting machine is water preparation
unit.

9.3.1) Cutting materials

 Metals
 Ceramics
 Textile
 Wood
 Leather

9.4) Advantages of water jet

 No heat-affected zone (HAZ)

 Sharp corners, bevels, pierce holes, and shapes with minimal inner radii are all possible
 Intricate cuts in material
 Water jets are capable of attaining accuracy down to (0.13 mm)
 Environment friendly

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9.5) Disadvantages of water jet

 Straight cut is not achieved

 Slow material removal rate
 Difficult to maintain high pressure
 Limited for special purposes

9.5.1) Limitations

 Cut can’t be less than diameter of jet

 Absence of depth control
 Nozzle wear is high
 In machining of soft materials , abrasive get embedded into the metals as a result aan additional
cleaning operation is required

9.6) References

[1] Hoogstrate A.M., van Luttervelt A.M.; Opportunitirs in Abrasive Water-Jet Machining, Annals of the
CIRP Vol. 46/2/1997

[2] Janković P., Radovanović M., Parameters of Abrasive Waterjet Cutting Process, 6th International
Conference ″Research and Development in Mechanical Industry″-RaDMI 2006, Budva, Montenegro,
2006, pp.343-346

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 Lab session: 10

Experiment Title:

10.1) Introduction of plasma arc cutting system and its machining system.

Plasma arc cutting process

The plasma arc cutting process is illustrated in Fig. The basic principle is that the arc formed between the
electrode and the workpiece is constricted by a fine bore, copper nozzle. This increases the temperature
and velocity of the plasma emanating from the nozzle. The temperature of the plasma is in excess of 20
000°C and the velocity can approach the speed of sound. When used for cutting, the plasma gas flow is
increased so that the deeply penetrating plasma jet cuts through the material and molten material is
removed in the efflux plasma.

fig : plasma arc cutting process

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The process differs from the oxy-fuel process in that the plasma process operates by using the arc to melt
the metal whereas in the oxy-fuel process, the oxygen oxidizes the metal and the heat from the exothermic
reaction melts the metal. Thus, unlike the oxy-fuel process, the plasma process can be applied to cutting
metals which form refractory oxides such as stainless steel, aluminium, cast iron and non-ferrous alloys.

Procedures

 Check the air pressure (should be about 70 p.s.i.).

 Attached the ground clamp to the metal being cut
 Turn the cutting on
 Adjust amperage to manufacturers specification for the metal and metal thickness
 Position shielding cut over metal
 Press the ignition button and establish the arc
 Move arc over cut line and cut. Consider using a guide bar if needed, will help make a straighter
cut. Hold the shielding cup and constricting nozzle 1/8″ to 1/4″ above the surface being cut. Do
not drag the shielding cup and constricting nozzle on the metal unless they are designed to be
used in this way.Tip: Make the cut on the waste side of the cut line.
 Use a slower travel speed for thicker metal. Direction of cutter (sideways, backward, forward) is
at the option of the cutter.
 Move the cutter as quickly as possible.
 If using compressed air, make sure it is free of moisture. There is an air filter available for the line
that can condition the air for improved plasma arc cutting quality.

Power source

The power source required for the plasma arc process must have a drooping characteristic and a high
voltage. Although the operating voltage to sustain the plasma is typically 50 to 60V, the open circuit
voltage needed to initiate the arc can be up to 400V DC. On initiation, the pilot arc is formed within the
body of the torch between the electrode and the nozzle. For cutting, the arc must be transferred to the
workpiece in the so-called 'transferred' arc mode. The electrode has a negative polarity and the workpiece
a positive polarity so that the majority of the arc energy (approximately two thirds) is used for cutting.

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Gas composition

In the conventional system using a tungsten electrode, the plasma is inert, formed using either argon,
argon-H2 or nitrogen. However, as described in Process variants, oxidising gases, such as air or oxygen,
can be used but the electrode must be copper with hafnium.The plasma gas flow is critical and must be set
according to the current level and the nozzle bore diameter. If the gas flow is too low for the current level,
or the current level too high for the nozzle bore diameter, the arc will break down forming two arcs in
series, electrode to nozzle and nozzle to workpiece. The effect of 'double arcing' is usually catastrophic
with the nozzle melting.

Process variants

Three variations of the process exist:

 low current plasma cutting

 high current plasma cutting
 cutting with water added

Advantages
There are many advantages for the plasma arc cutting process:

 small risk of changing the shape of the metal (called distortion)

 precise cutting
 slag-free cuts when working with aluminum, stainless steel and carbon steel
 works in all positions
 fast process
 works across many types of metals.
 do not require gas cylinders

Disadvantages
Some disadvantages of plasma arc cutting:

 creates a small bevel (7 degrees – approximate)

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  electrical shock risk when not operating safely
 requires clean air source
 needs electricity to operate so not completely portable
 not cost effective for very thick steel

References
http://weldguru.com/plasma-arc-cutting/

http://www.ebay.com/bhp/plasma-cutting-machine

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